WARRIOR 260EHLW12 User manual

ELECTRICAL HOIST

260EHLW12

260EHLW24

Assembly & Operating Instruction

CONTENTS

INTRODUCTION...................................................................................... 1

DANGER...................................................................................................2

HOIST ASSEMBLY AND MOUNTING.....................................................5

MOUNTING DRAWING............................................................................6

HOIST WORKING DEMONSTRATION....................................................6

REPLACING THE WIRE ROPE ...............................................................7

MAINTENANCE........................................................................................7

TROUBLE SHOOTING.............................................................................9

HOIST ASSEMBLY DRAWING .............................................................1 0

HOIST PARTS LIST...............................................................................1 1

SPECIFICATION....................................................................................1 2

INTRODUCTION

Congratulations on your purchase of a high quality winch. We design

and manufacture lifting winches to strict specifications, with proper use

and maintenance it will bring you many years of satisfying service.

WARNING - Read, understand and follow all danger, warning and

cautions instructions before operating this device. Failure to read

and follow these instructions may result in personal injury and/or

property damage.

Follow these general safety precautions:

•Confirm that the winch complies with the correct application.

•Ensure winch is secure and the rope is correctly wound on to

the drum.

•Do not use unsuitable pulleys or accessories.

•Do not use unsuitable rope if construction is weak strength or

has any defects.

•Pay attention to the earthing, it provides a path of least

resistance for electric current to reduce the risk of shock.

•Check the winch for smooth operation without load before

loading operation.

•Make sure the wire rope is wound evenly on the first layer on

the drum, unwind if mixed crossed windings occur.

1.The winch MUST never be used to lift, support or otherwise

transport people or animals.

2. The winch is NOT a load bearing / securing device and MUST

never hold a load for long periods of time or used for anchoring

transported pieces of equipment.

2. A minimum of five (5) wraps of rope around the drum at all times

is necessary to support the rated load.

3. We take no responsibility for the subsequent or poor performance

of this winch if oil or grease properties other than recommended are

used or any accident occurs through not reading and following the

these safety instructions.

DANGER

The following environmental conditions may

result in the possible causes of winch problems.

-Low temperature below -10°C, high temperature above 40°C

or humidity above 90% conditions.

-In heavy acid or salty conditions.

*Cause malfunction of spare pares.

-Exposed to rain or snow

*Cause rust or short circuit.

-In a organic chemistry or explosive power conditions.

*Cause explosion.

-In a heavy general powder conditions.

*Cause malfunction of performances.

SAFETY PRECAUTIONS

Always Pay attention to the following instructions. Obvious

mistakes in operation may result in personal injury or equipment

damage.

WINCH ASSEMBLY AND MOUNTING

1. Your winch is designed with a bolt pattern that is standard in this class of lifting

winch. Many winch mounting kits (Sold Separately) are available that utilize

this bolt pattern for the mounting channels. If you will utilize the mounting

channel you must ENSURE that it is mounted on a flat surface so that the three

major sections (motor, drum and gear housing) are properly aligned. Proper

alignment of the lifting winch will allow even distribution of the full rated load.

2. Pull out a few inches of cable from the drum. Now, using the remaining cap

screws, flat washer, lock washer and nut secure the hoist to the mounting

channel (Sold Separately)

3. Connect the battery and motor leads as the drawing above. Keep in mind that

every type of winch is different each other.

4. Assemble the clevis hook to the cable. Take off the pin from the clevis hook,

connect the clevis hook to the cable and mount the pin back to the clevis Hook.

5. Always use the hand saver (If Supplied) when free-spooling and re-spooling the

wire rope. Using the hand saver keeps your hands and fingers away from the

rotating drum.

6. Check for proper drum rotation. Pull out some cable from the drum. Press the

cable out button on the remote lead. If the drum is turning in the correct

direction releasing more cable then your connections are correct. If the drum is

turning and collecting more cable then the direction is incorrect and reverse the

leads on the motor. Repeat and check rotation.

MOUNTING DRAWING

The mounting drawing

CAUTION –Batteries contain gases which are flammable and explosive. Wear

eye protection during installation and remove all jewelry. Do not lean over

battery while making connections.

WINCH WORKING DEMONSTRATION

1. Grab the cable assembly and pull the cable to the desired length, then attach to

item being pulled.

Caution: Always leave at least five turns of cable on the drum; Review hoist safety

warnings and precautions on page 2,3 before continuing.

2. Insert the remote lead switch assembly plug into the control box socket.

3. Test-run winch is both forward and backwards directions, each direction for one or

two seconds.

4. While standing aside of the tow path, hold and operate the remote lead switch

assembly supplied by your choice. To reverse directions. Wait until the motor stops

completely before reversing directions.

5. When the pulling is complete, remove the remote lead switch assembly. From the

female connector of the directional valve and replace the female connectors cover.

REPLACING THE WIRE ROPE

If the wire rope has become worn or is beginning to show signs of damage, it must be

replaced before being used again.

1. Extend cable assembly to its full length. Note how the existing cable is connected

to the drum.

2. Remove old cable assembly and attach new one as the old cable connected to the

drum. Insert the end of the new rope and secure the screw.

3. Ensure that the new cable wraps in the same rotation direction as the old one.

The cable should leave the drum from the bottom, under the drum.

4. Retract Cable Assembly onto drum, first five wraps being careful not to allow

kinking, then steel cable must be wound onto the drum under a load of a light load.

WARNING - Only replace the wire rope with the identical replacement part

recommended by the manufacturer. Contact service agent.

MAINTENANCE

1. Periodically check the tightness of mounting bolts and electrical connections.

Remove all dirt or corrosion and always keep clean.

2. Do not attempt to disassemble the gear box. Repairs should be done by the

manufacturer or an authorized repair center.

3. The gearbox has been lubricated using a high temperature lithium grease and

is sealed at the factory. No internal lubrication or maintenance is required.

Classification of checks

Checking Item

Checking Method

Checking Reference

Daily

Periodical

One

month

Three

month

One

year

◎

Breaking of base wire

Visual

Less than 10%

◎

Decreasing of diameter

Visual

7% of normal diameter

max

◎

Kink phenomena

Visual

To be free from kink

phenomena

◎

Wire

Rope

Deforming or corrosion

Visual

To be not remarkable

◎

Fastening condition of end

Visual

To be sufficient for

hanging up of load

◎

Condition of rope

winding-in

Visual

To be free from irregular

winding

◎

Drum

Drum and flange

Visual

No deformation

◎

Wear of drum

Visual

To be free from

remarkable wearing

◎

Switch

Wire

Visual

No damage

◎

“IN”and “OUT”

Visual

No abnormality

◎

Working direction

Visual

No abnormality in lifting

◎

Operation

Abnormal sound

Hear out

No abnormal sound

◎

Over load test

Working

Existence of abnormalities

TROUBLE SHOOTING

When the winch fails to operate after several attempts, or if there is any fault while

operating check the following:

Symptom

Possible Cause

Remedy

Hoist will not

operate

Cut circuit

Check battery lead

Weak battery

Recharge or replace battery (Minimum

650CCA)

Damaged circuit breaker

Replace circuit breaker

Bad connection of wirings

Reconnect tightly

Damaged solenoid

Replace solenoid

Cut circuit on switch

Replace switch

Damaged motor or worn carbon brush

Replace motor or carbon brush

Dropt or lost motor wiring

Tighten wirings

Motor runs in

one direction

Broken wiring or bad connection

Reconnect or replace wiring

Damaged or stuck solenoid

Replace solenoid

Switch inoperative

Replace switch

Dropt or lost wiring

Replace wiring and tighten wirings

Hoist won’t lift

rated load

Considerable voltage drop exceeds by 10% of the

rated voltage of 12V DC or 24V DC

Correct leads size

Replace battery as bad condition

Clean and tighten the wirings

No brake

Damaged brake cam and disc

Replace brake cam and disc

Damaged gear box

Replace gear box

Dropt snatch ring

Replace snatch ring

Oil leakage at brake

Clean oil leakage

Damaged or inoperative spiral spring

Replace and position spiral spring

Brake distance

is too long

Worn or damaged brake

Replace or adjust brake

Oil leakage at brake

Clean oil leakage

Damaged gear

train

Hit by certain exterior force

Replace the damaged components

Damaged gear train

Replace the damaged components

Over load operation

Replace a new hoist

Motor runs

extremely hot

Long period of operation

Allow to cool

Damaged motor

Replace or repair motor

Damaged or inoperative brake

Replace or repair brake

Hoist vibrates

badly, noisy or

does not hold a

load

Damaged brake

Replace or repair brake

Mounting surface is not flat

Make sure mounting surface is flat

Tie bar is bent

Replace tie bar

WINCH ASSEMBLY

DRAWING

14 15

16 17

23 24

29 30

31 32

33 34 35

37 38

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